Apparatus for forming a prefabricated fireplace



p 1969 w. c. SOUTHERN ET m. 33, 66,000

APPARATUS FOR FORMING A PREFABRIC ATED FIREPLACE Filed Oct. 21, 1965 4 Sheets-Sheet 1 FIG. I FIG.2

I INVENTORJ WILLIAM C. SOUTHERN HERBERT M.WAGNER RAYMOND J. SCHOLZ M. WM

ATTORNEY Sept. 9, 1969 w. c. sou-menu E AL 3, 6,

APPARATUS FOR FORMING A PHEFABRICATED FIREPLACE Filed 0012. 21, 1965 4 Sheets-Sheet 2 N LN N N w o v u. 22 .n '0

Q IOU NI'O ID .0 I0 8 O O INVENTORB 2 N u c WlLLlAM asoumenu u. g a g HERBERT M.WAGNER RAYMOND J. SCHOLZ O 5 8y M. Um N ATTORNEY p 9. 1969 w. c. SOUTHERN :1- AL 3 66,000

APPARATUS FOR FORMING A PREPABRICATED FIREPLACE Filed 001;. 21, 1965 4 Sheets-Sheet 3 N INVENTORS WILLIAM C. SOUTHERN HERBERT M-WAGNER BY RAYMOND J- SCHOLZ ATTORNEY Sept. 9, 196? w, c, SOUTHERN ET AL 3,466,000

APPARATUS FOR FORMING A PREFABRICATED FIREPLACE Filed Oct. 21, 1965 4 Sheets-Sheet 4 INVENTORS WILLIAM C- SOUTHERN HERBERT M. WAGNER RAYMOND J- SCHOLZ Nu w mw um w m mm Nw mN n I nnnliliiinnn -I i D U Ill-L I I I E ow 3 w mm m 6 n2.

ATTORNEY United States Patent 3,466,000 APPARATUS FOR FORMING A PREFABRICATED FIREPLACE William C. Southern, Los Gatos, Herbert M. Wagner, Campbell, and Raymond J. Scholz, Los Altos, Calif., assignors to John Billmeyer, San Jose, Calif., trustee of the estate of Western Monolithics Inc., San Jose, Calif., a corporation of California, bankrupt Filed Oct. 21, 1965, Ser. No. 499,364 Int. Cl. B22d 19/00; B41b 11/54; F24b 1/18 US. Cl. 249-93 8 Claims ABSTRACT OF THE DISCLOSURE In the forming of a prefabricated fireplace, a fireplace form is formed with an interior wall grooved to simulate fireplace material so that the fireplace material cured therein has an exterior surface simulating the fireplace material. The fireplace form is constructed with pivotal panels for movement between a position for pouring fireplace material within the form and a position for removing cured fireplace material from the form. A reinforcing frame is disposed within the fireplace form and has a configuration conforming to a base section, a firebox section and a chimney section.

A preformed firebox is received by the form at the firebox section of the frame. At the chimney section of the frame, a flue is located within the form. A bottom plate is disposed in the form at the base section of the frame. Disposed in the form at the base section of the frame and extending between the bottom plate and the firebox is an ash receptacle. The reinforcing frame, the firebox, the flue, the bottom plate and the ash receptacle are imbedded within the fireplace material cured within the form.

The present invention relates in general to prefabricated construction of residences, and more particularly to a prefabricated fireplace.

An object of the present invention is to provide an improved prefabricated fireplace.

Another object of the present invention is to provide a prefabricated fireplace that is more durable than conventional masonry constructed fireplaces without sacrificing appearance.

Another object of the present invention is to simplify the construction of a prefabricated fireplace by providing a unitary reinforcing steel frame that is adaptable to protrude into the permanent foundation of the residence.

Another object of the present invention is to provide a prefabricated fireplace which is less susceptible to damage by earthquake, Windstorm, explosion and the like.

Another object of the present invention is to provide a prefabricated fireplace that has increased strength and, also, has a reduced weight.

Another object of the present invention is to provide a prefabricated fireplace that is installed rapidly and with ease of operation without sacrificing durability.

Another object of the present invention is to provide a prefabricated fireplace that is installed economically.

Another object of the present invention is to provide a prefabricated fireplace that is leak proof.

Other and further objects and advantages of the present invention will be apparent to one skilled in the art from the following description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a front perspective view of the prefabricated fireplace of the present invention.

FIG. 2 is a rear perspective view of the prefabricated fireplace of the present invention.

FIG. 3 is a perspective view of a reinforcing frame incorporated in the prefabricated fireplace of the present Patented Sept. 9, 1969 "ice invention illustrated with a jig for assembling the reinforcing frame.

FIG. 4 is an enlarged fragmentary perspective view taken substantially along line 44 of FIG. 3.

FIG. 5 is an enlarged fragmentary perspective view taken substantially along line 55 of FIG. 3.

FIG. 6 is an enlarged fragmentary perspective view taken substantially along line 66 of FIG. 3.

FIG. 7 is an exploded perspective view of a form for casting the prefabricated fireplace of the present invention with the reinforcing frame, firebox, and ash receptacle installed therein.

FIG. 8 is a fragmentary elevation view illustrating an arrangement for pivotally mounting the sides to the bottom of the form.

FIG. 9 is a top view of the form with the reinforcing frame, firebox and ash receptacle installed therein and ready for casting concrete therein to form the prefabricated fireplace of the present invention.

FIG. 10 is a vertical section of the assembly shown in FIG. 9 taken along lines 1010 of FIG. 9.

FIG. 11 is an enlarged vertical section taken along line 11-11 of FIG. 10.

Illustrated in FIGS. 1 and 2 is the prefabricated fireplace 10 of the present invention, which comprises a chimney 11, a firebox section 12 and a base 13.

In the construction of the prefabricated fireplace 10, a unitary reinforcing frame 15 (FIG. 3) is formed, which includes longitudinal members 20-23. Each longitudinal member has a base section designated by the sufiix a, a firebox section designated by the sufiix b, and a chimney section designated by the sufi'ix 0. Between the chimney sections of the longitudinal members 20-23 are disposed a plurality of longitudinally spaced, quadrangular braces 24-26. For longer size chimney, a greater number of transverse braces are employed. Between the base sections of the longtudinal members 20-23 are positioned adjacent longitudinally spaced, transversely disposed quadrangular braces 32 and 33. A transversely disposed three sided brace 34, which is spaced longitudinally from the brace 33, is disposed between the firebox sections of the longitudinal members 20-23. Between the firebox sections of the longitudinal members 20-23 are positioned, a transversely disposed three-sided brace 35 and longitudinally spaced transversely disposed quadrangular braces 36 and 37. The brace 36 has one pair of adjacent legs thereof disconnected. A pair of diagonally disposed bracing members 38 and 39 are located in parallel relation between the braces 24 and 25. Oppositely directed parallel diagonal bracing members 40 and 41 join the bracing members 38 and 39, respectively, and extend between the braces 24 and 36.

The frame 15 is a unitary structure in which all components thereof are welded to adjoining and adjacent components, excepting the pair of legs of the brace 37 previously mentioned. In addition to the foregoing, the frame 15 comprises U-shaped bolts 45-48. The bolts 45 and 47 are secured around the longitudinal members 20 and 23, and the bolts 46 and 47 are Secured around the longitudinal members 21 and 22. In addition, an oppositely directed pair of U-shaped claws 49 and 50 grips the longitudinal members 23 and 22, respectively.

In forming the frame 15, an assembly jig 50 (FIG. 3) is employed. The frame 15 is formed in the jig 50 in the horizontal position with its rear side as its jig supported portion. First, the longitudinal members 21 and 22 are placed on the jig 50. Now, the U-bolts 47 and 48 are disposed around the longitudinal members 20 and 21, respectively. Then, the transverse braces 24-26 are secured by welding to the longitudinal members 20 and 21 after placement in the designated notches in the jig 50 for proper location. At this time, the longitudinal members 21 and 22 are inserted in the U-bolts 47 and 48, respectively, and secured by welding to the transverse braces 24-26. Now, the U-bolts 45 and 46 are disposed around the longitudinal members 20 and 23, and the longitudinal members 21 and 22, respectively. The bracing members 32-27 are secured by welding to the longitudinal members 20-23 and the U-shaped claws 49 and 50 are attached to the longitudinal members 23 and 22, respectively, to complete the frame 15. The unconnected joint of the brace 37 remains disconnected.

In, FIGS. 7, 9 and is illustrated a form 60 for constructing the prefabricated fireplace 10. The form 60 is assembled from a plurality of lightweight aluminum panels. The lightweight aluminum panels include a plurality of upright section panels 61, which are joined together by suitable means, such as pins or nuts and bolts, to assume the fireplace configuration shown in FIGS. 7, 9 and 10. The upright section panels define the end wall patterns for the prefabricated fireplace. In addition thereto, bottom section panels 62 are secured together by suitable means, such as pins or nuts and bolts, to assume the fireplace configuration shown in FIGS. 7, 9 and 10, for defining the rear side wall pattern for the prefabricated fireplace. Similar panels, not shown, are provided to form the front side wall pattern, except for the firebox opening area. Also, edge panels 63 are joined by suitable means, such as pins or nuts and bolts, with certain of the upright section panels 61 to complete the pattern for the fireplace configuration.

The interior surfaces of the lightweight aluminum panels 61-63, excepting for the panels facing selected portions of the front side, are formed with grooves arranged to simulate a brick construction or other fireplace material (see FIG. 7), whereby concrete cast in the form 60 has the general appearance of brick or other fireplace material on the exterior surface thereof. A chimney crown plate 64 is mounted at the top end of the chimney section of the form 60.

For attaching the upright section panels 61 to the bottom section panels 62 so as to move the upright section panels 61 relative to the bottom section panels 62 between the upright and outwardly directed positions, the upright section panels 61 are hingedly attached to contiguous bottom section panels 62. For this purpose, a door hinge arrangement is provided between the junctions of adjacent bottom and upright section panels. As shown in FIGS. 7 and 8, axially aligned sleeve sections are secured by welding alternately to the conjoined upright and bottom section panels, which sleeve sections receive rods 65, whereby the upright section panels 61 are pivoted relative to the conjoined bottom section panels 62 for movement between the upright and outwardly directed positions (FIG. 8).

Once the fireplace form 60 is assembled in the manner described, the form 60 does not have to be disassembled and reassembled for further use. The hinged upright panels 61 swing down to release the cast and are raised upwardly in preparation for the succeeding fire-place casting.

A suitable stop 66 is pivotally attached by a pin to selected upright section panels 61 to serve as a stop by engaging a supporting surface when pivoted away from the associated upright section panels 61 (FIG. 8). The stops 66 serve to reduce tension on the hinge arrangement, when the upright panels 61 are extended outwardly to the outwardly directed position. In addition, floor space is conserved by not extending the upright section panels 61 to a horizontal position.

After the form 60 is constructed or prepared for reuse, a suitable thin film of oil is sprayed on the inside surface of the form 60 while the upright panels 61 are disposed in the outwardly directed position. If the form 60 has been previously used, it is to be swept clean before the spraying of the film of oil. Now, the reinforcing frame 15 is placed in the frame 60 with the U-shaped braces 34 and 35 having the free ends of the legs thereof extending upwardly (FIG. 7). For spacing the lower portions of the reinforcing frame 15, a predetermined distance from the bottom panels 62, suitably spaced scrap pieces of rebars may be welded to the reinforcing frame 15 as spacers. The upright panels 61 defining the chimney section of the fireplace are raised to the upright position. The brace 36, which has the disconnected adjacent legs, is bent outwardly to allow for the installation of a firebox 70. The firebox 70 is preformed and is made from suitable insulating material, such as fondu cement. The firebox 70' has a rectangular section 70a and an inwardly tapering section 70b that is disposed within the inwarded directed section of the reinforcing frame 15.

Channel shaped bars 71 and 72 are now extended across the upper section of the firebox 70 transversely thereof (FIG. 7). Eyebolts 74-77 are threaded through the channel bars 71 and 72 to be received in threaded engagement by suitable threaded embedded sockets, such as socket 78 shown in dotted lines in FIG. 7.

The firebox 70 is lifted by a suitable hoist, which has the cables thereof attached to the eyebolts 74-77. While lifted, the outer walls of the firebox 70, which will contact concrete, are painted with a suitable film of oil compound to allow for a small degree of expansion. Now, the firebox 70 is lowered (FIG. 7) into the fireplace form 60 with the channel bars 71 and 72 fastened to the exposed upper edges of the form 60 (FIG. 9), after the remaining panel sections 61 are raised to the upright position. All upright panel sections 61 in the raised or upright position are retained or locked in position by suitable nuts and bolts, or pins.

A U-shaped bottom plate 80 is installed at the base of the form 60 transversely thereof with the free end of the legs thereof projecting upwardly (FIG. 7). Suitable openings are formed in the legs of the U-shaped bottom plate 80 to receive respectively the longitudinal members 20-23 of the frame 15.

An ash receptable 81 is disposed within the form 60. The ash deposit receptacle 81 has a channel or U-shaped configuration with the legs thereof fitting snugly between the legs of the U-shaped bottom plate 80 and extending beyond the U-shaped bottom plate 80. The base of the ash receptacle 81 rests on the base of the U-shaped bottom plate 80 and extend therebeyond. Formed in the firebox 70 is an opening 82 (FIG. 10) at the base or lower wall thereof which receives a narrow neck or passageway 83 that is integrally formed with the ash receptacle 81. conventionally, a hinged door, not shown, covers the opening 82 from within the firebox 70. In this manner, ashes or fire residue pass through the opening 82, through the neck 83 and into the channel of the ash receptacle 81.

Formed in the rear wall of the ash receptacle 81 or the base of the U-shaped receptacle 81 is an opening 85 (FIG. 10). Seated in the opening 85 is a removable plug 86. A removable door 87 is fitted over the opening of the removable plug 86.

A channel plate 90 (FIGS. 9 and 10) is secured to the legs of the bottom plate 80 and the form 60 so as to retain the bottom plate 80 in a fixed position relative to the form 60. Further, a channel plate 91 (FIGS. 7, 9 and 10) is disposed transversely across the ash receptacle 81 and is secured to the form 60 by suitable screws or pins.

Cylindrical flue liner tiles 95 (FIGS. 9 and 10) of suitable material, such as terra cotta, are disposed within the reinforcing cage 15 through the open sections thereof and extend from the upper section of the chimney portion to the inwardly tapered section 70b of the firebox 70. A gap or space is provided between adjacent ends of succeeding tiles 95. Received by selected gaps between adjacent ends of succeeding tiles 95 are a plurality of hangers 96 (FIGS. 9-11) with elongated slots 97 (FIG. 11) formed therein. Midway between the chimney section of the fireplace, the gap between adjacent ends of the succeeding tiles 95 receives a hoisting cable so that the cable can be used by a hoist.

A relatively narrow rod 98 (FIGS. 9-11) is placed through the tubular openings of the flue liner tiles 95 and, also, through the slots 97 of the hangers 96. One end of the rod 98 projects outwardly of the form 60 and the other end of the rod 98 extends into the firebox 70. Attached to the channel bar 72 is a U-shaped bolt 99 that receives the portion of the rod 98 extending into the firebox 70.

The cable for the hoist is now looped around the rod 98 and the cable is raised to properly position the flue liners 95 through the rod 98. Each hanger 96 includes a horizontal bar 100 (FIG. 11), which supports a vertical bar 101 with the rod receiving slot 97 formed therein. Suitable manually operated eccentric cams 102 and 103 tre mounted on opposite ends of the horizontal bar 100 to engage the form 60 for maintaining the rod 98 at the adjusted position. Likewise, the bolt 99 is adjusted relative to the channel bar 72 for the same purpose.

After the bolt 99 and the hangers 96 are secured in position, the hoisting cable is removed from the rod 98 and the tiles 95 are moved axially to close the gap previously occupied by the hoisting ctble. The crown plate 64 (FIGS. 7, 9 and is placed in position at the open or free end of the chimney section within the form 60. A hanger plate 105 (FIGS. 9 and 10) is mounted on the form 60 and surrounds the end of the rod 98 projecting out of the chimney section of the form 60 to support the same in the adjusted position.

A insulating wall 106 (FIGS. 9 and 10) of preferably fondu cement is now placed at the inwardly tapering section 70b of the firebox to enclose the upper constricting portion thereof joining the flue tiles 95 with the rectangular section 70a of the firebox 70. In this manner, a narrow passageway is defined from the partially open rectangular section 70a of the firebox 70 to the flue tiles 95 through the tapering section 70b of the firebox 70. Sheet metal flashing, when required by a building code, may be placed in the form 60 for embedding in the concrete of the fireplace to extend from the base of the fireplace to chimney portion up to the caves of the roof of a house. The claws 49 and 50 are secured to the longitudinal members 23 and 22, respectively, of the reinforcing frame 15 by welding. A clamp strap 110 is fastened around the form 60 and the disconnected adjacent legs of the brace 36 are now welded together.

Before the casting of concrete into form 60, a suitable piece of material, such as plywood, is placed over the opening of the firebox 70 at the rectangular section 70:: thereof. Concrete is now poured or cast into the form 60 starting at the chimney section. While the concrete is cast, continuous vibration thereof take place. The casting of the concrete in the chimney section toward the shoulder continues until the chimney section is completely cast.

Without casting concrete directly onto the insulation wall 106 of the firebox 70, the concrete chute is swung so that concrete is poured onto the material covering the opening of the firebox 70. Concrete is shoveled from the material covering the opening of the firebox 70 around the firebox and base. The concrete is continuously v1- brated while cast.

The hangers 96 are removed from the form 60 and the rod 98 is removed from the form 60 from the chimney end thereof. The upper end of the chimney has concrete troweled thereon to extend slightly beyond the form 60. At the lower end of the chimney, concrete is troweled even with the sides of the form. The covering above the opening of the firebox 70 is removed.

After the concrete is cured, the channel bars 71, 72 and 91 are removed. The plug 86 is removed and the chimney crown plate 64 is removed. The upright sectional panels 61 are pivoted to the outwardly directed 6 position. The hoist is attached to the tie bolts 4548 to lift the fireplace 10 from the form 60. The fireplace 10 is now transported to the residence for installation. A damper is installed in the fireplace 10 between the insulating wall 106 and the end of the tubular flue liners for manual control by an operator.

It is to be understood that modifications and variations of the embodiment of the invention disclosed herein may be resorted to without departing from the spirit of the invention and the scope of the appended claims.

Having thus described our invention, what we claim as new and desire to protect by Letters Patent is:

1. An assembly for forming a prefabricated fireplace comprising a fireplace form adapted for receiving fireplace material, a reinforcing frame disposed within said fireplace form, said reinforcing frame being formed with a base section, a firebox section and a chimney section, a preformed firebox received by said form at the firebox section of said frame, flue defining means disposed in said form at the chimney section of said frame, said form including a bottom plate at the base section of said frame, and an ash receiving receptacle disposed in said form at the base section of said frame and extending between said bottom plate and said firebox, said firebox and said ash receiving receptacle being formed with openings in communication with one another to establish an ash deposit passageway therebetween, said reinforcing frame, said firebox, said flue defining means, said bottom plate and said ash receiving receptacle to be imbedded within said fireplace material.

2. An assembly for forming a prefabricated fireplace comprising a fireplace form adapted for receiving fireplace material, said fireplace form being formed with pivotal panels for movement between a position for casting fireplace material within said form and a position for removing cured fireplace material from said form, a reinforcing frame disposed within siad fireplace form, said reinforcing frame being formed with a base section, a firebox section and a chimney section, a preformed firebox received by said form at the firebox section of said frame, flue defining means disposed in said form at the chimney section of said frame, said form including a bottom plate at the base section of said frame, and an ash receiving receptacle disposed in said form at the base section of said frame and extending between said botom plate and said firebox, said firebox and said ash receiving receptacle being formed with openings in communication with one another to establish an ash deposit passageway therebetween, said reinforcing frame, said firebox, said flue defining means, said bottom plate and said ash receiving receptacle to be imbedded within said fireplace material.

3. An assembly for forming a prefabricated fireplace comprising a fireplace form adapted for receiving fireplace material, said fireplace form being formed with a predetermined configuration to simulate predetermined fireplace material so that fireplace material cured therein has an exterior surface simulating the predetermined fireplace material, said fireplace form being formed with pivotal panels for movement between a position for easting fireplace material within said form and a position for removing cured fireplace material from said form, a reinforcing frame disposed within said fireplace form, said reinforcing frame being formed with a base section, a firebox section and a chimney section, a preformed firebox received by said form at the firebox section of said frame, a flue defining means disposed in said form at the chimney section of said frame, said form including a bottom plate at the base section of said frame, and an ash receiving receptacle disposed in said form at the base section of said frame and extending between said bottom plate and said firebox, said firebox and said ash receiving receptacle being formed with openings in communication with one another to establish an ash deposit passageway therebetween, said reinforcing frame, said firebox,

said flue defining means, said bottom plate, and said ash receiving receptacle to be imbedded within said fireplace material.

4. An assembly for forming a prefabricated fireplace as claimed in claim 1, said fireplace form being formed with a grooved interior surface having a predetermined configuration to simulate predetermined fireplace material so that fireplace material cured therein has an exterior surface simulating the predetermined fireplace material.

5. An assembly for forming a prefabricated fireplace as claimed in claim 1, said fireplace form being formed with pivotal panels for movement between a position for casting fireplace material within said form and a position for removing cured fireplace material from said form.

6. An assembly for forming a prefabricated fireplace as claimed in claim 1, and means secured to said imbedded frame and projecting outwardly therefrom to be attached to a hoisting cable.

7. An assembly for forming a prefabricated fireplace as claimed in claim 2, and means secured to the chimney section of said imbedded frame and projecting outwardly therefrom to be attached to a hoisting cable.

8. An assembly for forming a prefabricated fireplace as claimed in claim 1, a rod extending through said flue defining means for adjusting the position thereof within said fireplace form, and means carried by said fireplace form and attached to said rod for adjustably positioning said rod to regulate the position of said flue defining means.

References Cited UNITED STATES PATENTS 983,678 2/1911 Burbank 24993 1,905,897 4/1933 Cahill 249172 2,857,646 10/1958 McLaughlin 24983 3,259,679 7/1966 Nielsen 29983 3,301,249 1/1967 Hendricks 249-91 J. SPENCER OVERHOLSER, Primary Examiner R. D. BALDWIN, Assistant Examiner U.S. Cl. X.R. 126-420; 249-l72 

